Removing and installing tandem pump, engine codes AXB, AXC, BRR, BRS — VW

Removing and installing tandem pump, engine codes AXB, AXC, BRR, BRS
DANGER!
The tandem pump may, under no circumstances, be dismantled as the vacuum part could otherwise malfunction.
This would result in the failure of the brake booster.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Hand vacuum pump
VAS 6213
Water drainage container
V.A.G 1390/1
Spring-type clip pliers
VAS 5024 A
Removing
WARNING
The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
Wear protective gloves.
Vehicles with fuel preheating
Pull supply hose
1
(white marking) and return hose
2
(blue marking) off fuel filter.
Connect
hand vacuum pump
VAS 6213
with
water drainage container
V.A.G 1390/1
to return hose
2
.
Operate
hand vacuum pump
VAS 6213
until no more fuel comes out of return hose. Make sure that no fuel is sucked into
hand vacuum pump
.
Vehicles without fuel preheating
Pull supply hose off fuel filter.
Separate return hose connection (blue marking)/return line (brown) next to fuel filter.
Connect
hand vacuum pump
VAS 6213
with
water drainage container
V.A.G 1390/1
to return hose.
Operate
hand vacuum pump
VAS 6213
until no more fuel comes out of return hose. Make sure that no fuel is sucked into
hand vacuum pump
.
Continuation for all vehicles
Remove coolant expansion tank and place to one side (leaving hoses connected).
Remove charge air pipe between intake manifold and charge air cooler.
Detach vacuum line
1
of brake servo from tandem pump
4
.
Detach fuel supply line
2
from tandem pump
4
.
Unscrew securing bolts
arrows
.
Remove tandem pump
4
from cylinder head.
Pull tandem pump upwards slightly and remove fuel line
3
from tandem pump
4
.
Installing
Installation is carried out in the reverse order. When installing, note the following:
Note
Ensure that tandem pump coupling seats properly in shaft.
Always renew tandem pump seals.
Install tandem pump and tighten upper securing bolts.
Tighten lower securing bolts .
Connect return hose (blue or blue marking)
3
and vacuum line
1
to tandem pump.
Connect supply hose (black) to supply connection
2
and brake servo vacuum line
1
to tandem pump
4
.
Vehicles with fuel preheating
Connect supply hose
Item
and return hose
Item
to fuel filter.
Vehicles without fuel preheating
Pull supply hose
Item
off fuel filter.
Connect return hose to return line.
Continuation for all vehicles
Install charge air pipe between intake manifold and charge air cooler.
Secure coolant expansion tank.
Note
The tandem pump must always be checked for internal leaks between fuel side and oil side after reinstalling a used tandem pump
Chapter
.
Bleeding fuel system
Maintenance
Booklet
19.1
.
Carry out road test and read all event memories
Vehicle diagnostic tester
.
Specified torques
Bolts securing tandem pump to cylinder head
Rep. gr.
15
Cylinder head; Assembly overview – cylinder head